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Philip, Ragnartz, and Axel Staffanson. "Improving the product development process with additive manufacturing." Thesis, Mälardalens högskola, Akademin för innovation, design och teknik, 2018. http://urn.kb.se/resolve?urn=urn:nbn:se:mdh:diva-40344.
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The following report consists of a master thesis (30 credits) within product development. The thesis is written by Philip Ragnartz and Axel Staffanson, both studying mechanical engineering at Mälardalens University. Developing new components for a production line is costly and time consuming as they must be made from manual measurements and must go through all the conventional manufacturing (CM) steps. Eventual design mistakes will be discovered after the component have been manufactured and tested. To fix the design a completely new component must be designed and therefore double the overall lead time. The purpose of this thesis is to establish how additive manufacturing (AM) can best be used to minimize the cost and lead time in the development of new components. The study was performed by looking at the current product development process in the automotive industry at a large company, here by referred to as company A. 56 components already manufactured at company A´s own tools department was examined and compared to different AM methods. The aim of this was to get a larger pool of data to get an average on production time and cost and see how this differ to the different AM methods. Additionally, two work holders were more closely examined in a case study. Work holder one is a component in the production line that occasionally must be remanufactured. It was examined if this problem could be solved with a desktop plastic printer to hold up for a production batch. Work holder two was the development of a new component, this was to examine the use of printing the component in an early stage impact the development process. The findings from this study is that AM can today not be used in a cost efficient way in manufacturing or development of simple components. This is due to the cost of a metal 3D-printer is still very high, and the building material even higher. This results in components that gets very expensive to make compared to producing them with CM. For design evaluation to be cost efficient there will have to be a design fault in over 12 % of the newly design components for it to be cost effective to print the design for validation before sending it to be manufactured. There are however a lot bigger potential savings in the lead time. Producing the end product with a metal 3D-printer can cut down the lead time up to 85 %. This is thanks to the fact that the printer will produce the component all in one step and therefore not get stuck in between different manufacturing processes. The same goes for design evaluation with printing the component in plastic to confirm the design and not risk having to wait for the component to be manufactured twice. Despite the facts that it is not cost efficient to use AM there are other factors that play an important role. To know that the designed components will work will create a certainty and allow the development process to continue. In some cases it will also allow the designer to improve the design to function better even if the first design would have worked. As AM is expanding machines and build materials will become cheaper. Eventually it will become cheaper to 3D-print even simple components compared to CM. When this occurs, a company cannot simply buy a 3D-printer and make it profitable. There is a learning curve with AM that will take time for the designers to adapt to. Therefore, it is good to start implementing it as soon as possible as it allows for more intricate designs and require experience to do so.
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Han, Tianyang. "Ultrasonic Additive Manufacturing of Steel: Process, Modeling, andCharacterization." The Ohio State University, 2020. http://rave.ohiolink.edu/etdc/view?acc_num=osu1607039366940573.
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Strano, Giovanni. "Multi-objective optimisation in additive manufacturing." Thesis, University of Exeter, 2012. http://hdl.handle.net/10871/8405.
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Additive Manufacturing (AM) has demonstrated great potential to advance product design and manufacturing, and has showed higher flexibility than conventional manufacturing techniques for the production of small volume, complex and customised components. In an economy focused on the need to develop customised and hi-tech products, there is increasing interest in establishing AM technologies as a more efficient production approach for high value products such as aerospace and biomedical products. Nevertheless, the use of AM processes, for even small to medium volume production faces a number of issues in the current state of the technology. AM production is normally used for making parts with complex geometry which implicates the assessment of numerous processing options or choices; the wrong choice of process parameters can result in poor surface quality, onerous manufacturing time and energy waste, and thus increased production costs and resources. A few commonly used AM processes require the presence of cellular support structures for the production of overhanging parts. Depending on the object complexity their removal can be impossible or very time (and resources) consuming. Currently, there is a lack of tools to advise the AM operator on the optimal choice of process parameters. This prevents the diffusion of AM as an efficient production process for enterprises, and as affordable access to democratic product development for individual users. Research in literature has focused mainly on the optimisation of single criteria for AM production. An integrated predictive modelling and optimisation technique has not yet been well established for identifying an efficient process set up for complicated products which often involve critical building requirements. For instance, there are no robust methods for the optimal design of complex cellular support structures, and most of the software commercially available today does not provide adequate guidance on how to optimally orientate the part into the machine bed, or which particular combination of cellular structures need to be used as support. The choice of wrong support and orientation can degenerate into structure collapse during an AM process such as Selective Laser Melting (SLM), due to the high thermal stress in the junctions between fillets of different cells. Another issue of AM production is the limited parts’ surface quality typically generated by the discrete deposition and fusion of material. This research has focused on the formation of surface morphology of AM parts. Analysis of SLM parts showed that roughness measured was different from that predicted through a classic model based on pure geometrical consideration on the stair step profile. Experiments also revealed the presence of partially bonded particles on the surface; an explanation of this phenomenon has been proposed. Results have been integrated into a novel mathematical model for the prediction of surface roughness of SLM parts. The model formulated correctly describes the observed trend of the experimental data, and thus provides an accurate prediction of surface roughness. This thesis aims to deliver an effective computational methodology for the multi- objective optimisation of the main building conditions that affect process efficiency of AM production. For this purpose, mathematical models have been formulated for the determination of parts’ surface quality, manufacturing time and energy consumption, and for the design of optimal cellular support structures. All the predictive models have been used to evaluate multiple performance and costs objectives; all the objectives are typically contrasting; and all greatly affected by the part’s build orientation. A multi-objective optimisation technique has been developed to visualise and identify optimal trade-offs between all the contrastive objectives for the most efficient AM production. Hence, this thesis has delivered a decision support system to assist the operator in the "process planning" stage, in order to achieve optimal efficiency and sustainability in AM production through maximum material, time and energy savings.
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Joshi, Anay. "Geometric Complexity based Process Selection and Redesign for Hybrid Additive Manufacturing." University of Cincinnati / OhioLINK, 2017. http://rave.ohiolink.edu/etdc/view?acc_num=ucin151091601846356.
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Ding, J. "Thermo-mechanical analysis of wire and arc additive manufacturing process." Thesis, Cranfield University, 2012. http://dspace.lib.cranfield.ac.uk/handle/1826/7897.
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Conventional manufacturing processes often require a large amount of machining and cannot satisfy the continuously increasing requirements of a sustainable, low cost, and environmentally friendly modern industry. Thus, Additive Manufacturing (AM) has become an important industrial process for the manufacture of custom-made metal workpieces. Among the different AM processes, Wire and Arc Additive Manufacture (WAAM) has the ability to manufacture large, low volume metal work-pieces due to its high deposition rate. In this process, 3D metallic components are built by depositing beads of weld metal in a layer by layer fashion. However, the non-uniform expansion and contraction of the material during the thermal cycle results in residual stresses and distortion. To obtain a better understanding of the thermo-mechanical performance of the WAAM process, a study based on FE simulation was untaken in this thesis. The mechanism of the stress generation during the deposition process was analysed via a 3D transient thermo-mechanical FE model which is verified with experimental results. To be capable of analysing the thermo-mechanical behaviour of large-scale WAAM components, an efficient FE approach was developed which can significantly reduce the computational time. The accuracy of this model was validated against the transient model as well as experimental measurements. With the help of the FE models studies on different deposition parameters, deposition sequences and deposition strategies were carried out. It has been proved that the residual stresses and the distortions are possible to be reduced by using optimised deposition parameters and sequences. In addition, a robot path generation prototype has been developed to help efficiently integrate these optimised process settings in the real-wold WAAM process.
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Luo, Xiaoming. "Process planning for an Additive/Subtractive Rapid Pattern Manufacturing system." [Ames, Iowa : Iowa State University], 2009. http://gateway.proquest.com/openurl?url_ver=Z39.88-2004&rft_val_fmt=info:ofi/fmt:kev:mtx:dissertation&res_dat=xri:pqdiss&rft_dat=xri:pqdiss:3389124.
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Sequeira, Almeida P. M. "Process control and development in wire and arc additive manufacturing." Thesis, Cranfield University, 2012. http://dspace.lib.cranfield.ac.uk/handle/1826/7845.
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This thesis describes advancements in the modelling, optimisation, process control and mechanical performance of novel high deposition rate gas metal arc welding processes for large scale additive manufacturing applications. One of the main objectives of this study was to develop fundamental understanding of the mechanisms involved during processing with particular focus on single layer welds made of carbon steel using both pulsed-current gas metal arc welding and cold metal transfer processes. The effects of interactions between critical welding process variables and weld bead and plate fusion characteristics are studied for single and multi-layers. It was shown that several bead and plate fusion characteristics are strongly affected by the contact tip to work distance, TRIM, wire feed speed, wire feed speed to travel speed ratio, and wire diameter in pulsed-current gas metal arc welding. The arc-length control, dynamic correction and the contact tip to work distance are shown to strongly influence the weld bead geometry in the cold metal transfer process. This fundamental knowledge was essential to ensure the successful development of predictive interaction models capable of determining the weld bead geometry from the welding process parameters. The models were developed using the least-squares analysis and multiple linear regression method. The gas tungsten constricted arc welding process was utilised for the first time for out-of-chamber fabrication of a large scale and high-quality Ti-6Al-4V component. The main focus was, however, in the use of the cold metal transfer process for improving out-of-chamber deposition of Ti-6Al-4V at much higher deposition rates. The effect of the cold metal transfer process on the grain refinement features in the fusion zone of single layer welds under different torch gas shielding conditions was investigated. It was shown that significant grain refinement occurs with increasing helium content. The morphological features and static mechanical performance of the resulting multi-layered Ti-6Al-4V walls were also examined and compared with those in gas tungsten constricted arc welding. The results show that a considerable improvement in static tensile properties is obtained in both testing directions with cold metal transfer over gas tungsten constricted arc welding. It was suggested that this improvement in the mechanical behaviour could be due to the formation of more fine-grained structures,which are therefore more isotropic. The average ultimate tensile strength and yield strength of the as-deposited Ti-6Al-4V material processed via cold metal transfer meet the minima specification values recommended for most Ti-6Al-4V products. Neutron diffraction technique was used to establish the effect of repeated thermo-mechanical cycling on the generation, evolution and distribution of residual stresses during wire and arc additive manufacturing. The results show a significant redistribution of longitudinal residual stresses along both the substrate and multi-bead with repeated deposition. However, a nearly complete relaxation occurs along the built, once the base plate constraint is removed.
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Hayagrivan, Vishal. "Additive manufacturing : Optimization of process parameters for fused filament fabrication." Thesis, KTH, Lättkonstruktioner, 2018. http://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-238184.
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An obstacle to the wide spread use of additive manufacturing (AM) is the difficulty in estimating the effects of process parameters on the mechanical properties of the manufactured part. The complex relationship between the geometry, parameters and mechanical properties makes it impractical to derive an analytical relationship and calls for the use of a numerical model. An approach to formulate a numerical model in developed in this thesis. The AM technique focused in this thesis is fused filament fabrication (FFF). A numerical model is developed by recreating FFF build process in a simulation environment. Machine instructions generated by a slicer to build a part is used to create a numerical model. The model acts as a basis to determine the effects of process parameters on the stiffness and the strength of a part. Determining the stiffness of the part is done by calculating the response of the model to a uniformly distributed load. The strength of the part depends on it's thermal history. The developed numerical model serves as a basis to implement models describing the relation between thermal history and strength. The developed model is suited to optimize FFF parameters as it encompass effects of all FFF parameters. A genetic algorithm is used to optimize the FFF parameters for minimum weight with a minimum stiffness constraint.<br>Ett hinder för att additiv tillverkning (AT), eller ”3D-printing”, ska få ett bredare genomslag är svårigheten att uppskatta effekterna av processparametrar på den tillverkade produktens mekaniska prestanda. Det komplexa förhållandet mellan geometri och processparametrar gör det opraktiskt och komplicerat att härleda analytiska uttryck för att förutsäga de mekaniska egenskaperna. Alternativet är att istället använda numeriska modeller. Huvudsyftet med denna avhandling har därför varit att utveckla en numerisk modell som kan användas för att förutsäga de mekaniska egenskaperna för detaljer tillverkade genom AT. AT-tekniken som avses är inriktad på Fused Filament Fabrication (FFF). En numerisk modell har utvecklats genom att återskapa FFF-byggprocessen i en simuleringsmiljö. Instruktioner (skriven i GCode) som används för att bygga en detalj genom FFF har här översatts till en numerisk FE-modell. Modellen används sen för att bestämma effekterna av processparametrar på styvheten och styrkan hos den tillverkade detaljen. I detta arbete har strukturstyvheten hos olika detaljer beräknats genom att utvärdera modellens svar för jämnt fördelade belastningsfall. Styrkan, vilket är starkt beroende på den tillverkade detaljens termiska historia, har inte utvärderats. Den utvecklade numeriska modellen kan dock fungera som underlag för implementering av modeller som beskriver relationen mellan termisk historia och styrka. Den utvecklade modellen är anpassad för optimering av FFF-parametrar då den omfattar effekterna av alla FFF-parametrar. En genetisk algoritm har använts i detta arbete för att optimera parametrarna med avseende på vikt för en given strukturstyvhet.
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Nickchen, Tobias [Verfasser]. "Deep learning for automating additive manufacturing process chains / Tobias Nickchen." Paderborn : Universitätsbibliothek, 2021. http://d-nb.info/1234058804/34.
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Karande, Niraj Nitin. "Adoption of Additive Manufacturing in process industries : A case study." Thesis, Uppsala universitet, Industriell teknik, 2020. http://urn.kb.se/resolve?urn=urn:nbn:se:uu:diva-426129.
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This paper explores the adoption of additive manufacturing technology in the process industries and tries to provide a holistic view about the preference and scope of this technology in the process industry sector. There has been vast literature about use of this technology in the automobile, aerospace, and medical sector. This study will help us to understand how Additive Manufacturing technology is shaping the other process industries and explore if it has same significance. To address the research questions qualitative research method is used in this study with semi-structured interviews with the respondents in process industries and Additive Manufacturing suppliers. All respondents are selected using purposive sampling and remote interviews were conducted with them.The first finding of this study was that additive manufacturing can neither be stated directly as radical or disruptive innovation because this technology has shown both radical as well as disruptive changes in the process industry. Secondly, this technology is adopted in the process industry based on the three innovation attributes: relative advantage, trialability, and observability. Following this, there is discussion on important barriers and how companies are taking efforts to overcome this barrier and adopt this technology easily. Further, this study implies that there is still an immense scope to explore this technology to reap its full benefits. This study gives understanding to AM suppliers that small-scale firms in process industry could be a possible direction to explore for more business opportunities apart from automobile and aerospace industry. For potential researchers in additive manufacturing, this study stands to give understanding for adoption pattern and innovation attributes for which it is valued.
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Alkadi, Faez. "DEVELOPMENT OF A CONFORMAL ADDITIVE MANUFACTURING PROCESS AND ITS APPLICATION." University of Akron / OhioLINK, 2019. http://rave.ohiolink.edu/etdc/view?acc_num=akron1556282142803521.
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Johansson, Matilda, and Robin Sandberg. "How Additive Manufacturing can Support the Assembly System Design Process." Thesis, Tekniska Högskolan, Högskolan i Jönköping, JTH, Industriell organisation och produktion, 2016. http://urn.kb.se/resolve?urn=urn:nbn:se:hj:diva-30887.
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In product manufacturing, assembly approximately represents 50% of the total work hours. Therefore, an efficient and fast assembly system is crucial to get competitive advantages at the global market and have the right product quality. Today, the verification of the assembly system is mostly done by utilizing software based simulation tools even though limitations have been identified. The purpose of this thesis is to identify when the use of additive manufacturing technology could be used in assessing the feasibility of the assembly system design. The research questions were threefold. First, identifying limitations that are connected with the used assembly simulation tools. Secondly, to investigate when additive manufacturing can act as a complement to these assembly simulations. Finally, to develop a framework that will assist the decision makers when to use additive manufacturing as a complement to assembly simulations. The researchers used the method of case study combined with a literature review. The case study collected data from semi-structured interviews, which formed the major portion of the empirical findings. Observations in a final assembly line and the additive manufacturing workshop provided valuable insights into the complexity of assembly systems and additive manufacturing technologies. In addition, document studies of the used visualization software at the case company resulted in an enhanced understanding of the current setting. The case study findings validate the limitations with assembly simulations described in theory. The most frequent ones are related to visibility, positioning, forces needed for the assembly operator, and accessibility between different parts. As both theory and case study findings are consistent in this respect, simulation engineers should be conscious of when to find other methods than simulation for designing the assembly system. One such alternative method is the utilization of additive manufacturing. The thesis outlines a number of situations where additive manufacturing indeed could act as a complement to assembly simulation. The authors argue that the results and findings to a large degree are applicable to other industries as the automotive sector is very global and competitive in nature and encompasses a large variety of complex assembly operations. A structured framework was also developed that could act as a decision support. The framework takes into account three dimensions that are crucial for the decision; (1) the assembly simulation limitation, (2) the context of the assembly and which parts are involved and (3) the possible limitations of additive manufacturing in the specific context. This impartial decision framework could help companies with complex assembly systems to know when to use additive manufacturing, as well as for which parts and subparts additive manufacturing is applicable. To increase the longevity of the decision framework, new improvements of assembly simulation tools and additive manufacturing technologies, respectively, should be incorporated in the framework.
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Wang, Lening. "Process and Quality Modeling in Cyber Additive Manufacturing Networks with Data Analytics." Diss., Virginia Tech, 2021. http://hdl.handle.net/10919/104655.
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A cyber manufacturing system (CMS) is a concept generated from the cyber-physical system (CPS), providing adequate data and computation resources to support efficient and optimal decision making. Examples of these decisions include production control, variation reduction, and cost optimization. A CMS integrates the physical manufacturing equipment and computation resources via Industrial Internet, which provides low-cost Internet connections and control capability in the manufacturing networks. Traditional quality engineering methodologies, however, typically focus on statistical process control or run-to-run quality control through modeling and optimization of an individual process, which makes it less effective in a CMS with many manufacturing systems connected. In addition, more personalization in manufacturing generates limited samples for the same kind of product designs, materials, and specifications, which prohibits the use of many effective data-driven modeling methods. Motivated by Additive Manufacturing (AM) with the potential to manufacture products with a one-of-a-kind design, material, and specification, this dissertation will address the following three research questions: (1) how can in situ data be used to model multiple similar AM processes connected in a CMS (Chapter 3)?
(2) How to improve the accuracy of the low-fidelity first-principle simulation (e.g., finite element analysis, FEA) for personalized AM products to validate the product and process designs (Chapter 4) in time?
(3) And how to predict the void defect (i.e., unmeasurable quality variables) based on the in situ quality variables.
By answering the above three research questions, the proposed methodology will effectively generate in situ process and quality data for modeling multiple connected AM processes in a CMS. The research to quantify the uncertainty of the simulated in situ process data and their impact on the overall AM modeling is out of the scope of this research. The proposed methodologies will be validated based on fused deposition modeling (FDM) processes and selective laser melting processes (SLM). Moreover, by comparing with the corresponding benchmark methods, the merits of the proposed methods are demonstrated in this dissertation. In addition, the proposed methods are inherently developed with a general data-driven framework. Therefore, they can also potentially be extended to other applications and manufacturing processes.<br>Doctor of Philosophy<br>Additive manufacturing (AM) is a promising advanced manufacturing process that can realize the personalized products in complex shapes with unprecedented materials. However, there are many quality issues that can restrict the wide deployment of AM in practice, such as voids, porosity, cracking, etc. To effectively model and further mitigate these quality issues, the cyber manufacturing system (CMS) is adopted. The CMS can provide the data acquisition functionality to collect the real-time process data which directly or indirectly related to the product quality in AM. Moreover, the CMS can provide the computation capability to analyze the AM data and support the decision-making to optimize the AM process. However, due to the characteristics of AM process, there are several challenges effectively and efficiently model the AM data. First, there are many one-of-a-kind products in AM, and leads to limited observations for each product that can support to estimate an accurate model. Therefore, in Chapter 3, I would like to discuss how to jointly model personalized products by sharing the information among these similar-but-non-identical AM processes with limited observations. Second, for personalized product realization in AM, it is essential to validate the product and process designs before fabrication quickly. Usually, finite element analysis (FEA) is employed to simulate the manufacturing process based on the first-principal model. However, due to the complexity, the high-fidelity simulation is very time-consuming and will delay the product realization in AM. Therefore, in Chapter 4, I would like to study how to predict the high-fidelity simulation result based on the low-fidelity simulation with fast computation speed and limited capability. Thirdly, the defects of AM are usually inside the product, and can be identified by the X-ray computed tomography (CT) images after the build of the AM products. However, limited by the sensor technology, CT image is difficult to obtain for online (i.e., layer-wise) defect detection to mitigate the defects. Therefore, as an alternative, I would like to investigate how to predict the CT image based on the optical layer-wise image, which can be obtained during the AM process in Chapter 5. The proposed methodologies will be validated based on two types of AM processes: fused deposition modeling (FDM) processes and selective laser melting processes (SLM).
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Banerjee, Soumya. "Development of a novel toner for electrophotography based additive manufacturing process." Thesis, De Montfort University, 2011. http://hdl.handle.net/2086/5037.
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This thesis is intended to conduct feasibility study of producing 3D objects by printing thermoplastic elastomer using electrophotography technique and thereafter sintering the whole layer using infrared light source .The term Selective laser printing (SLP) has been coined by the author for this new process. This thesis provides the feasibility of developing experimental toner using thermoplastic toner using both mono and dual component print engines.
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Jonsson, Vannucci Tomas. "Investigating the Part Programming Process for Wire and Arc Additive Manufacturing." Thesis, Luleå tekniska universitet, Institutionen för teknikvetenskap och matematik, 2019. http://urn.kb.se/resolve?urn=urn:nbn:se:ltu:diva-74291.
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Wire and Arc Additive Manufacturing is a novel Additive Manufacturing technology. As a result, the process for progressing from a solid model to manufacturing code, i.e. the Part Programming process, is undeveloped. In this report the Part Programming process, unique for Wire and Arc Additive Manufacturing, has been investigated to answer three questions; What is the Part Programming process for Wire and Arc Additive Manufacturing? What are the requirements on the Part Programming process? What software can be used for the Part Programming process? With a systematic review of publications on Wire and Arc Additive Manufacturing and related subjects, the steps of the Part Programming process and its requirements have been clarified. The Part Programming process has been used for evaluation of software solutions, resulting in multiple recommendations for implemented usage. Verification of assumptions, made by the systematic review, has been done by physical experiments to give further credibility to the results.
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Wu, Hongjian. "Process Modeling and Planning for Robotic Cold Spray Based Additive Manufacturing." Thesis, Bourgogne Franche-Comté, 2020. http://www.theses.fr/2020UBFCA026.
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La projection à froid (Cold spray, CS) est une technologie de dépôt de revêtement à l'état solide qui a récemment été appliquée comme processus de fabrication additive (Additive manufacturing, AM) pour fabriquer des composants individuels. Ce procédé potentiel attire de plus en plus de l'attention en raison de ses avantages : efficacité de formage élevée, basse température de travail et absence de changement de phase des matériaux. Ces avantages peuvent permettre à la projection à froid de former des objets de grand volume pour devenir un procédé de fabrication additive efficace. De nos jours, de nouvelles avancées dans la fabrication additive à froid (Cold spray additive manufacturing, CSAM) nécessitent de nouvelles implémentations de processus pour améliorer la précision et la flexibilité de fabrication. Par conséquent, le but de cette étude est d'améliorer la méthode additive utilisant la projection à froid grâce à la modélisation et à la planification du processus robotique CS. Le travail de cette thèse se compose en trois parties.Premièrement, des efforts ont été consacrés à la conception et à la mise en œuvre d'un nouveau cadre pour la technique CSAM. Dans cette partie, un concept de système modulaire est présenté. Ici, le système CSAM actuel est décomposé en différents modules afin de comprendre les relations physiques et fonctionnelles entre les éléments clés de l'ensemble du système. Cette modularité physique et fonctionnelle est une nécessité indispensable pour promouvoir les processus AM hybrides. De nouveaux modules, tels que le module de mesure in-situ, le module inter-processus peuvent être intégrés pour offrir plus de possibilités au processus CS conventionnel. Il est révélé que la modularité du système est adaptée pour révolutionner la méthode et technique CSAM. On peut voir que pour exploiter pleinement le potentiel de cette approche, des efforts sont encore nécessaires pour intégrer et coordonner davantage de technologies à l'aide du cadre modulaire proposé.Deuxièmement, une nouvelle approche est présentée pour simuler le dépôt. Ici, un modèle géométrique tridimensionnel du profil de revêtement basé sur la distribution gaussienne est développé. Le modèle est combiné avec la trajectoire du robot et les paramètres de traitement pour simuler l'évolution des dépôts. En outre, il peut offrir une prédiction précise du profil dans la plate-forme de programmation hors ligne du robot, en particulier dans le cas des effets d'ombre, ce qui permet l'intégration de la programmation du robot avec la simulation pour mieux contrôler le processus de revêtement. Les résultats des vérifications numériques et expérimentales montrent que cette méthode proposée a une bonne précision de prédiction.Enfin, par rapport à la stratégie actuelle de formation de volume basée sur le volume (par exemple, une méthode basée sur la tessellation), cette étude propose une nouvelle stratégie qui prend en compte les caractéristiques et les paramètres cinématiques de la projection à froid pour améliorer la construction de couches stables pour l’obtention de forme 3D. La simulation et les expériences sont menées pour la vérification de la méthode. Les essais comparatives créés par couches ont une meilleure précision de forme que celle des méthodes existantes. Cela implique que la méthode proposée fait de la projection à froid un processus additif efficace pour la création additive de formes 3D<br>Cold spray (CS) is a solid-state coating deposition technology that has recently been applied as an additive manufacturing (AM) process to fabricate individual components. This potential AM process is attracting more and more attention because of its advantages: high-forming efficiency, low temperature, and no phase changing of materials. These advantages make CS able to form large-volume objects to become an efficient and effective AM process. Nowadays, new advances in cold spray additive manufacturing (CSAM) call for new process implementation to improve the manufacturing accuracy and flexibility. Therefore, the purpose of this study is to enhance CS-based AM through the modeling and planning of the robotic CS process. The work of this thesis consists of three parts.Firstly, efforts have been dedicated to design and implement a new framework for CSAM. In this part, a concept of modular system is presented. Here, the current CSAM system is decomposed into different modules in order to understand the physical and functional relationships between the key elements of the entire system. This physical and functional modularity is an indispensable necessity to promote hybrid AM processes. New modules, such as in-situ measurement module, inter-process module can be integrated into the framework to bring more possibilities to the conventional CS process. It is revealed that system modularity is suitable to revolutionize the CSAM method and conduction. It can be seen that to fully exert the potential of CSAM, efforts are still required to integrate and coordinate more technologies with the help of the proposed modular framework.Secondly, a novel approach is presented to simulate the CS deposition. Here, a three-dimensional geometric model of the coating profile based on Gaussian distribution is developed. The model is combined with robot trajectory and processing parameters to simulate the evolving CS deposits. In addition, it can offer accurate profile prediction in the robot off-line programming platform, especially in case of shadow effects, which enables the integration of robot programming with simulation to better control the coating process. The results of both numerical and experimental verifications show that this proposed method has a good prediction accuracy for practice.At last, compared with the current bulk-based volume-forming strategy (e.g. a tessellation-based method), this study proposes a new spray strategy that considers the characteristics and kinematic parameters of cold spray to enhance stable layer building for 3D shape forming. Both simulation and experiments are conducted for method verification. Layer built benchmarking test objects have better shape accuracy than that of existing methods. This implies that the proposed method makes CS a real and layer-by-layer ready AM process for 3D shape forming
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Hehr, Adam J. "Process Control and Development for Ultrasonic Additive Manufacturing with Embedded Fibers." The Ohio State University, 2016. http://rave.ohiolink.edu/etdc/view?acc_num=osu1461153463.
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Juhasz, Michael J. "In and Ex-Situ Process Development in Laser-Based Additive Manufacturing." Youngstown State University / OhioLINK, 2020. http://rave.ohiolink.edu/etdc/view?acc_num=ysu15870552278358.
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Butt, Javaid. "A novel additive manufacturing process for the production of metal parts." Thesis, Anglia Ruskin University, 2016. http://arro.anglia.ac.uk/701001/.
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The majority of additive manufacturing methods use different materials for the production of parts. The current methods employing powder metals have their limitations and are very expensive. This research presents a novel additive manufacturing process for the generation of modest and high quality metal parts. The procedure, referred to as Composite Metal Foil Manufacturing, is a blend of Laminated Object Manufacturing and soldering/brazing strategies. A calculated model of a machine in view of the new process has been outlined and its parts accepted for usefulness either by experimentation or recreations. The viability of the new process is accepted with lap-shear testing, peel testing, microstructural examination and tensile testing. Distinctive metals, such as copper and aluminium, with shifting thicknesses were used to demonstrate the adaptability of the procedure. Composites of aluminium and copper were additionally delivered and tried for their mechanical properties to show the flexibility of the process. The outcomes of the research attained have been promising and show that the new process is not just fit for delivering astounding metal parts efficiently but can create more grounded parts contrasted with customary subtractive techniques. The comparative tensile testing demonstrated that the parts created by the new process had force values that were 11%, 8% and 11% higher than the parent copper, aluminium and composite examples individually. This shows that the procedure has the capability to be a solid competitor in the field of metal prototyping. It has been demonstrated that the proposed procedure can have a gigantic effect as it has lessened the confinements, for example, cost, pace, material determinations and beyond. The additive manufacturing identified with the generation of metal parts using the new process can work with an extensive variety of metals under typical conditions regardless of their joining capacities. The feedback that parts delivered by added substance fabrication techniques are not sufficiently strong for genuine applications can without much of a stretch is hushed with the obtained trial results. Applications can extend from little bespoke parts to large scale functional products that can be utilized with minimal post handling.
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Ghazizadeh, Ali, and Suraj Lakshminarasimhaiah. "Additive manufacturing and its impacts on manufacturing industries in the future concerning the sustainability of AM." Thesis, Mälardalens högskola, Akademin för innovation, design och teknik, 2021. http://urn.kb.se/resolve?urn=urn:nbn:se:mdh:diva-56058.
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With the emergence of modern technologies in manufacturing processes, companies need to adapt themselves to these technologies to stay competitive. Additive Manufacturing is one of the upcoming technologies which will bring major changes to the manufacturing process. AM (Additive Manufacturing) offers flexibility in design, production size, customization, etc., Even though there are numerous advantages from the implementation of AM technologies less than 2% of the manufacturing industries use them for production. The purpose of the thesis was to study the impact of AM on manufacturing industries in 5-10 years and the barriers it is facing for widespread diffusion. Additionally, its impact on Sustainability aspects is also studied. A literature review was conducted to understand the current AM processes, their applications in different manufacturing sectors, their impact on business strategies, operations, and Product Life cycle. From the study, it was concluded that AM technologies are still in their maturing state and has a lot of uncertainties that it must overcome. The most notable barriers being implementation costs, limited materials, and protection of Intellectual property. The thesis also presents the projection for AM in 2030. AM is advantageous for Environmental and Economic sustainability with very little research on Societal sustainability.
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Roberson, David Mathew III. "Sensor-based Online Process Monitoring in Advanced Manufacturing." Thesis, Virginia Tech, 2016. http://hdl.handle.net/10919/72911.
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Effective quality improvement in the manufacturing industry is continually pursued.
There is an increasing demand for real-time fault detection, and avoidance of destructive
post-process testing. Therefore, it is desirable to employ sensors for in-process monitoring,
allowing for real-time quality assurance. Chapter 3 describes the application of sensor
based monitoring to additive manufacturing, in which sensors are attached to a desktop
model fused deposition modeling machine, to collect data during the manufacturing
process. A design of experiments plan is conducted to provide insight into the process,
particularly the occurrence of process failure. Subsequently, machine learning
classification techniques are applied to detect such failure, and successfully demonstrate
the future potential of this platform and methodology. Chapter 4 relates the application of
online, image-based quantification of the surface quality of workpieces produced by
cylindrical turning. Representative samples of cylindrical shafts, machined by turning
under various conditions, are utilized, and an apparatus is constructed for acquiring images
while the part remains mounted on a lathe. The surface quality of these specimens is
analyzed, employing an algebraic graph theoretic approach, and preliminary regression
modeling displays an average surface roughness (Ra) prediction error of less than 8%.
Prediction occurs in less than 2 seconds, showing the capability for future application in a
real-time, quality control setting. Both of these cases, in additive manufacturing and in
turning, are validated using real experimental data and analysis, showing application of
sensor-based online process monitoring in multiple manufacturing areas.<br>Master of Science
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Francis, Zachary Ryan. "The Effects of Laser and Electron Beam Spot Size in Additive Manufacturing Processes." Research Showcase @ CMU, 2017. http://repository.cmu.edu/dissertations/909.
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In this work, melt pool size in process mapped in power-velocity space for multiple processes and alloys. In the electron beam wire feed and laser powder feed processes, melt pool dimensions are then related to microstructure in the Ti-6Al-4V alloy. In the electron beam wire feed process, work by previous authors that related prior beta grain size to melt pool area is extended and a control scheme is suggested. In the laser powder feed process, in situ thermal imaging is used to monitor melt pool length. Real time melt pool length measurements are used in feedback control to manipulate the resulting microstructure. In laser and electron beam direct metal additive manufacturing, characteristics of the individual melt pool and the resulting final parts are a product of a variety of process parameters. Laser or electron beam spot size is an important input parameter that can affect the size and shape of a melt pool, and has a direct influence on the formation of lack-of-fusion and keyholing porosity. In this work, models are developed to gain a better understanding of the effects of spot size across different alloys and processes. Models are validated through experiments that also span multiple processes and alloys. Methods to expand the usable processing space are demonstrated in the ProX 200 laser powder bed fusion process. In depth knowledge of process parameters can reduce the occurrence of porosity and flaws throughout processing space and allow for the increased use of non-standard parameter sets. Knowledge of the effects of spot size and other process parameters can enable an operator to expand the usable processing space while avoiding the formation of some types of flaws. Based on simulation and experimental results, regions where potential problems may occur are identified and process parameter based solutions are suggested. Methods to expand the usable processing space are demonstrated in the ProX 200 laser powder bed fusion process. In depth knowledge of process parameters can reduce the occurrence of porosity and flaws throughout processing space and allow for the increased use of non-standard parameter sets.
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Paul, Ratnadeep. "Modeling and Optimization of Powder Based Additive Manufacturing (AM) Processes." University of Cincinnati / OhioLINK, 2013. http://rave.ohiolink.edu/etdc/view?acc_num=ucin1378113813.
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Dasari, Vinod Kumar. "Machine Learning to Detect Anomalies in the Welding Process to Support Additive Manufacturing." Thesis, Linköpings universitet, Institutionen för datavetenskap, 2021. http://urn.kb.se/resolve?urn=urn:nbn:se:liu:diva-176357.
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Additive Manufacturing (AM) is a fast-growing technology in manufacturing industries. Applications of AM are spread across a wide range of fields. The aerospace industry is one of the industries that use AM because of its ability to produce light-weighted components and design freedom. Since the aerospace industry is conservative, quality control and quality assurance are essential. The quality of the welding is one of the factors that determine the quality of the AM components, hence, detecting faults in the welding is crucial. In this thesis, an automated system for detecting the faults in the welding process is presented. For this, three methods are proposed to find the anomalies in the process. The process videos that contain weld melt-pool behaviour are used in the methods. The three methods are 1) Autoencoder method, 2) Variational Autoencoder method, and 3) Image Classification method. Methods 1 and 2 are implemented using Convolutional-Long Short Term Memory (LSTM) networks to capture anomalies that occur over a span of time. For this, instead of a single image, a sequence of images is used as input to track abnormal behaviour by identifying the dependencies among the images. The method training to detect anomalies is unsupervised. Method 3 is implemented using Convolutional Neural Networks, and it takes a single image as input and predicts the process image as stable or unstable. The method learning is supervised. The results show that among the three models, the Variational Autoencoder model performed best in our case for detecting the anomalies. In addition, it is observed that in methods 1 and 2, the sequence length and frames retrieved per second from process videos has effect on model performance. Furthermore, it is observed that considering the time dependencies in our case is very beneficial as the difference between the anomalous and the non anomalous process is very small
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Buga, Vlad, and Roysten Jason Dsouza. "In-process monitoring for Electron Beam Additive Manufacturing using an infrared camera system." Thesis, KTH, Industriell produktion, 2018. http://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-245064.
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Additive Manufacturing (AM) is being embraced at a rapid rate, mainly due to its advantages over conventional machining. These include the possibility to create parts with complex geometries, while minimizing waste. The exponential growth of the technology has brought about challenges in quality assurance, which has proved a key barrier to large scale adoption. Developing in-process monitoring techniques for AM is an ongoing challenge, and is still a long way off from the more established techniques developed for conventional machining. Previous research has brought about instances, where the technology has been implemented, with the focus on titanium alloys. This study aims to contribute to the research being carried out within in-process monitoring, and focusses on the Electron Beam Melting (EBM) process. The material being monitored is Inconel 625, to increase the scope of research to higher temperature ranges. The most suitable monitoring technology and vendor for the equipment, is narrowed down through a review of previous literature and market research. Experimental trials to analyze the performance of the monitoring technique with Inconel 625 are carried out. The extracted data is then analyzed using image processing, which gives interesting results with regards to temperature fluctuations over successive layers of the build. The events within the build process for a layer, show interesting deviations in temperature, which are mapped and presented as graphs. The after-rake event, shows a particularly large deviation, which is then attributed to differential heating of the metal powder during the rake phase. This observation is supported by noticing ‘cold-spots’ in extracted images of the build. The results are discussed, and future scope for the study is conveyed. The intention of this study is to provide a base for further research into in-process monitoring for higher temperature ranges and contribute to the development of real-time process monitoring for AM.<br>“Additive manufacturing” (AM) eller “friformsframställning” har snabbt ökat i omfattning, främst tack vare dess fördelar jämfört med konventionell bearbetning. Fördelarna inkluderar möjligheten att tillverka delar med komplexa geometrier medan slöseri minimeras. Den exponentiella tillväxten av tekniken har medfört utmaningar inom kvalitetssäkring, vilket har visat sig vara ett hinder för storskalig anpassning. Utveckling av processövervakningstekniker för AM är en pågående utmaning, och ligger efter i utveckling jämfört med de mer etablerade teknikerna som utvecklats för konventionell bearbetning. Tidigare forskning har visat fall där tekniken har implementerats med fokus på titanlegeringar. Denna studie syftar till att bidra till den forskning som genomförs inom processövervakning och fokuserar på EBM-processen (Electronic Beam Melting). Materialet som övervakas är Inconel 625, för att expandera forskningsområdet till högre temperaturområden. Den mest lämpliga övervakningstekniken och leverantör av utrustning väljs ut genom en gransking av tidigare litteratur och en marknadsundersökning. Experimentella försök för att analysera övervakningsteknikens prestanda med Inconel 625 utförs. De extraherade data analyseras sedan med bildbehandling, vilket ger intressanta resultat med avseende på temperaturfluktuationer över successiva lager av byggobjektet. Händelserna inom byggprocessen för ett lager visar intressanta avvikelser i temperatur, vilka kartläggs och presenteras som grafer. Tillståndet efter räfsning visar en särskilt stor avvikelse, som sedan tillskrivs differentialvärme av metallpulvret under räfsningsfasen. Denna observation stöds genom att notera "cold-spots" i extraherade bilder av byggobjektet. Resultaten diskuteras och vidare omfång för studien framförs. Avsikten med denna studie är att ta fram en grund för vidare forskning i processövervakning för högre temperaturområden och bidra till utvecklingen av realtidsprocessövervakning för AM.
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Ahsan, AMM Nazmul. "Study on the Relationship between Process Plan and Resource Requirement in Additive Manufacturing." Thesis, North Dakota State University, 2018. https://hdl.handle.net/10365/28404.
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Resource consumption in additive manufacturing (AM) is often tied with the physical attribute of the fabricated part. Thus, optimizing the processes plan for minimum part fabrication resource requirement is a matter of great interest. In this thesis, the hierarchical nature of the AM process plan steps are emphasized and both build direction and material deposition direction are optimized while considering the resource requirement. A novel combined two-step optimization methodology is presented to determine optimal build direction for the object and material deposition direction for layers while considering minimum contour plurality, surface quality, build height, fabrication factor, and layer contour concavity to compensate for the fabrication and resource limitations. Furthermore, a concurrent process plan optimization methodology is presented focusing on fabrication complexity resulting from part geometry. Implementation of the proposed methodologies on several example parts indicates substantial reduction of their total build time.
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Siraskar, Nandkumar S. "Adaptive Slicing in Additive Manufacturing Process using a Modified Boundary Octree Data Structure." University of Cincinnati / OhioLINK, 2012. http://rave.ohiolink.edu/etdc/view?acc_num=ucin1353155811.
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Thompson, John Ryan. "RELATING MICROSTRUCTURE TO PROCESS VARIABLES IN BEAM-BASED ADDITIVE MANUFACTURING OF INCONEL 718." Wright State University / OhioLINK, 2014. http://rave.ohiolink.edu/etdc/view?acc_num=wright1401699643.
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Wu, Michael. "Transfer Learning Approach to Powder Bed Fusion Additive Manufacturing Defect Detection." DigitalCommons@CalPoly, 2021. https://digitalcommons.calpoly.edu/theses/2324.
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Laser powder bed fusion (LPBF) remains a predominately open-loop additive manufacturing process with minimal in-situ quality and process control. Some machines feature optical monitoring systems but lack automated analytical capabilities for real-time defect detection. Recent advances in machine learning (ML) and convolutional neural networks (CNN) present compelling solutions to analyze images in real-time and to develop in-situ monitoring.
Approximately 30,000 selective laser melting (SLM) build images from 31 previous builds are gathered and labeled as either “okay” or “defect”. Then, 14 open-sourced CNN were trained using transfer learning to classify the SLM build images. These models were evaluated by F1 score and down selected to the top 3 models. The top 3 models were then retrained and evaluated using Dietterich’s 5x2 cross-validation and compared with pairwise student t-tests. The pairwise t-test results show no statistically significant difference in performance between VGG- 19, Xception, and InceptionResNet. All models are strong candidates for future development and refinement.
Additional work addresses the entire model development process and establishes a foundation for future work. Collaborations with computer science students has produced an image pre-processing program to enhance as-taken SLM images. Other outcomes include initial work to overlay CAD layer images and preliminary hardware integration plan for the SLM machine. The results from this work have demonstrated the potential of an optical layer-wise image defect detection system when paired with a CNN.
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Palmer, Andrew. "The Design and Development of an Additive Fabrication Process and Material Selection Tool." Master's thesis, University of Central Florida, 2009. http://digital.library.ucf.edu/cdm/ref/collection/ETD/id/3635.
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In the Manufacturing Industry there is a subset of technologies referred to as Rapid Technologies which are those technologies that create the ability to compress the time to market for new products under development . Of this subset, Additive Fabrication (AF), or more commonly known as Rapid Prototyping (RP), acquires much attention due to its unique and futuristic approach to the production of physical parts directly from 3D CAD data, CT or MRI scans, or data from laser scanning systems by utilizing various techniques to consecutively generate cross-sectional layers of a given thickness upon the previous layer to form 3D objects. While Rapid Prototyping is the most common name for the production technology it is also referred to as Additive Manufacturing, Layer Based Manufacturing, Direct Digital Manufacturing, Free-Form Fabrication, and 3-Dimensional Printing. With over 35 manufacturers of Additive Fabrication equipment in 2006 , the selection of an AF process and material for a specific application can become a significant task, especially for those with little or no technical experience with the technology and to add to this challenge, many of the various processes have multiple material options to select from . This research was carried out in order to design and construct a system that would allow a person, regardless of their level of technical knowledge, to quickly and easily filter through the large number of Additive Fabrication processes and their associated materials in order to find the most appropriate processes and material options to create physical reproductions of any part. The selection methodology used in this paper is a collection of assumptions and rules taken from the author's viewpoint of how, in real world terms, the selection process generally takes place between a consumer and a service provider. The methodology uses those assumptions in conjunction with a set of expert based rules to direct the user to a best set of qualifying processes and materials suited for their application based on as many or as few input fields the user may be able to complete.<br>M.S.<br>Department of Industrial Engineering and Management Systems<br>Engineering and Computer Science<br>Industrial Engineering MS
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Parrot, Jérôme. "W.A.M, Wire Additive Manufacturing : champs des possibles et utilisation raisonnée." Thesis, Ecole centrale de Nantes, 2018. http://www.theses.fr/2018ECDN0047/document.
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Dans la Fabrication Additive (FA), les objets en trois dimensions sont créés couche par couche en joignant chaque couche à la précédente. Pour les pièces métalliques, il existe trois méthodes principales : le lit de poudre, le dépôt de poudre et le dépôt de fil. Ce dernier utilise de manière optimale le matériau contrairement aux autres procédés, ce qui le rend très intéressant industriellement. En effet, avec la poudre, le rapport entre la poudre utilisée et la poudre fondue n’est pas égal à un, en opposition à l’utilisation de fil. Afin de garantir la bonne fusion du métal, plusieurs méthodes existent déjà, notamment l’utilisation de lasers ou d’arcs électriques. Ce manuscrit présente une nouvelle approche de dépôt de fil utilisant l’énergie inductive pour les applications de fabrication additive (WIAM). Cette approche ne fait pas appel à un stockage du matériau fondu. Au lieu de cela, la pointe d’un fil métallique est fondue par un système de chauffage par induction. L’énergie inductive est également utilisée pour obtenir un gradient thermique optimal entre l’extrémité du fil et le substrat ou la couche précédente. Les travaux de thèse concernent le développement de cette approche par un modèle numérique et sa validation expérimentale. Il est montré que le système de chauffage par induction est capable de faire fondre la pointe du fil et de chauffer le substrat pour créer un dépôt approprié. La microstructure après dépôt de fabrication additive pour un matériau en acier inoxydable a été étudiée. Ces résultats ont été comparés avec la méthode WAM. On montre que le système de chauffage par induction donne une microstructure à très faible porosité et une microstructure sans changement soudain de composition. Ces résultats préliminaires indiquent que la fabrication additive par fil métallique avec induction (WIAM) est susceptible de constituer un processus approprié pour la FA, mais qu’elle doit encore être développée<br>In Additive Manufacturing (AM), three dimensionalobjects are built layer by layer by joining each layer to the previous one. For metal parts, there are three main methods: powder bed, powder depositionand wire deposition. This latter makes optimal use of the material in contrast to other processes, which makes it very interesting industrially. Indeed, with powder,the ratio between powder used and powder meltedis not equal to one, in opposition of the use of wire. In order to ensure the proper melting of the metal, several methods already exist, including the use of lasers or electric arc. This manuscript presents a novel approach of wire deposition using inductive energy for additive manufacturing applications (WIAM). This approach does not make use of a storage of the molten material. Instead, the tip of a metal wire is melted by an induction heating system. Inductive energy is also used to obtain an optimal thermal gradient between the tip of the wire and the substrate or previous layer. Thesis work concerns the development of this approach by a numerical model, and its experimental validation. It shows that the induction heating system is able to melt the tip of the wire and heat the substrate to create suitable deposition. The microstructure of additive manufacturing stainless steel has been studied. These results have been compared with WAM method. It is shown that the induction heating system gives a microstructure with very low porosities and a microstructure without a sudden change of composition. These preliminary results indicate that Wire Induction Additive Manufacturing (WIAM) is likely to a suitable process for AM but it still needs to be developed
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Sheridan, Luke Charles. "An Adapted Approach to ProcessMapping Across Alloy Systems and Additive Manufacturing Processes." Wright State University / OhioLINK, 2016. http://rave.ohiolink.edu/etdc/view?acc_num=wright1471861921.
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Brandemyr, Gabriella. "Powder bed additive manufacturing using waste products from LKAB's pelletization process : A pre-study." Thesis, Luleå tekniska universitet, Institutionen för teknikvetenskap och matematik, 2019. http://urn.kb.se/resolve?urn=urn:nbn:se:ltu:diva-75421.
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This report is the result of a bachelor thesis project executed at Luleå University of Technology(LTU). The purpose of the project was to investigate the possibility to use the metal powder wasteproducts from LKAB’s pelletizing process for additive manufacturing as this would meaneconomic benefits for the sake of LKAB as well as environmental benefits.Two different powders were used in the experiments and were referred to as crush and dust. Theexperiments were made through the selective laser melting (SLM) method with varying laserparameters to observe their effect. These included the laser power and laser speed. Scanningelectron microscope (SEM), Energy Dispersive X-Ray Spectroscopy (EDS) and opticalmicroscopy were used for the analysis of the samples.The analysis of the chemical compositions showed that the powders were inhomogeneous anddiffered from each other. The crush powder contained phosphor and carbon which was lacking inthe dust and also had higher amounts of silicon and potassium. In spite of the inhomogeneouspowder and getting some agglomerations of half-melted grains on the tracks, the tracks tended tobe mostly homogenous. It was also observed that the tracks have a higher amount of carboncompared to the powder which probably derives from the substrate plate.The adherence of the tracks was greatest at a laser power between 200-300 W and a laser scanningspeed 0.5-1.75 m/min.The metal powder waste products from LKAB’s pelletization process could likely be used inadditive manufacturing, however, more work is needed in order to ensure the obtained results andcontinue with further experiments.
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Zhang, Fangjin. "Optimising additive manufacturing for fine art sculpture and digital restoration of archaeological artefacts." Thesis, Loughborough University, 2014. https://dspace.lboro.ac.uk/2134/14886.
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Additive manufacturing (AM) has shown itself to be beneficial in many application areas, including product design and manufacture, medical models and prosthetics, architectural modelling and artistic endeavours. For some of these applications, coupling AM with reverse engineering (RE) enables the utilisation of data from existing 3D shapes. This thesis describes the application of AM and RE within sculpture manufacture, in order to optimise the process chains for sculpture reproduction and relic conservation and restoration. This area poses particular problems since the original artefacts can often be fragile and inaccessible, and the finishing required on the AM replicas is both complex and varied. Several case studies within both literature and practical projects are presented, which cover essential knowledge of producing large scale sculptures from an original models as well as a wide range of artefact shapes and downstream finishing techniques. The combination of digital technologies and traditional art requires interdisciplinary knowledge across engineering and fine art. Also, definitions and requirements (e.g. 'accuracy'), can be applied as both engineering and artistic terms when specifications and trade-offs are being considered. The thesis discusses the feasibility for using these technologies across domains, and explores the potential for developing new market opportunities for AM. It presents and analyses a number of case study projects undertaken by the author with a view to developing cost and time models for various processes used. These models have then been used to develop a series of "process maps", which enable users of AM in this area to decide upon the optimum process route to follow, under various circumstances. The maps were validated and user feedback obtained through the execution of two further sculpture manufacturing projects. The thesis finishes with conclusions about the feasibility of the approach, its constraints, the pros and cons of adopting AM in this area and recommendations for future research.
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Snelling, Dean Andrew Jr. "A Process for Manufacturing Metal-Ceramic Cellular Materials with Designed Mesostructure." Diss., Virginia Tech, 2015. http://hdl.handle.net/10919/51606.
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The goal of this work is to develop and characterize a manufacturing process that is able to create metal matrix composites with complex cellular geometries. The novel manufacturing method uses two distinct additive manufacturing processes: i) fabrication of patternless molds for cellular metal castings and ii) printing an advanced cellular ceramic for embedding in a metal matrix. However, while the use of AM greatly improves the freedom in the design of MMCs, it is important to identify the constraints imposed by the process and its process relationships.
First, the author investigates potential differences in material properties (microstructure, porosity, mechanical strength) of A356 — T6 castings resulting from two different commercially available Binder Jetting media and traditional 'no-bake' silica sand. It was determined that they yielded statistically equivalent results in four of the seven tests performed: dendrite arm spacing, porosity, surface roughness, and tensile strength. They differed in sand tensile strength, hardness, and density.
Additionally, two critical sources of process constraints on part geometry are examined: (i) depowdering unbound material from intricate casting channels and (ii) metal flow and solidification distances through complex mold geometries. A Taguchi Design of Experiments is used to determine the relationships of important independent variables of each constraint. For depowdering, a minimum cleaning diameter of 3 mm was determined along with an equation relating cleaning distance as a function of channel diameter. Furthermore, for metal flow, choke diameter was found to be significantly significant variable.
Finally, the author presents methods to process complex ceramic structure from precursor powders via Binder Jetting AM technology to incorporate into a bonded sand mold and the subsequently casted metal matrix. Through sintering experiments, a sintering temperature of 1375 °C was established for the ceramic insert (78% cordierite). Upon printing and sintering the ceramic, three point bend tests showed the MMCs had less strength than the matrix material likely due to the relatively high porosity developed in the body. Additionally, it was found that the ceramic metal interface had minimal mechanical interlocking and chemical bonding limiting the strength of the final MMCs.<br>Ph. D.
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Snelling, Jr Dean Andrew. "A Process for Manufacturing Metal-Ceramic Cellular Materials with Designed Mesostructure." Diss., Virginia Tech, 2003. http://hdl.handle.net/10919/51606.
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The goal of this work is to develop and characterize a manufacturing process that is able to create metal matrix composites with complex cellular geometries. The novel manufacturing method uses two distinct additive manufacturing processes: i) fabrication of patternless molds for cellular metal castings and ii) printing an advanced cellular ceramic for embedding in a metal matrix. However, while the use of AM greatly improves the freedom in the design of MMCs, it is important to identify the constraints imposed by the process and its process relationships.
First, the author investigates potential differences in material properties (microstructure, porosity, mechanical strength) of A356 — T6 castings resulting from two different commercially available Binder Jetting media and traditional 'no-bake' silica sand. It was determined that they yielded statistically equivalent results in four of the seven tests performed: dendrite arm spacing, porosity, surface roughness, and tensile strength. They differed in sand tensile strength, hardness, and density.
Additionally, two critical sources of process constraints on part geometry are examined: (i) depowdering unbound material from intricate casting channels and (ii) metal flow and solidification distances through complex mold geometries. A Taguchi Design of Experiments is used to determine the relationships of important independent variables of each constraint. For depowdering, a minimum cleaning diameter of 3 mm was determined along with an equation relating cleaning distance as a function of channel diameter. Furthermore, for metal flow, choke diameter was found to be significantly significant variable.
Finally, the author presents methods to process complex ceramic structure from precursor powders via Binder Jetting AM technology to incorporate into a bonded sand mold and the subsequently casted metal matrix. Through sintering experiments, a sintering temperature of 1375 °C was established for the ceramic insert (78% cordierite). Upon printing and sintering the ceramic, three point bend tests showed the MMCs had less strength than the matrix material likely due to the relatively high porosity developed in the body. Additionally, it was found that the ceramic metal interface had minimal mechanical interlocking and chemical bonding limiting the strength of the final MMCs.<br>Ph. D.
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Scime, Luke Robson. "Methods for the Expansion of Additive Manufacturing Process Space and the Development of In-Situ Process Monitoring Methodologies." Research Showcase @ CMU, 2018. http://repository.cmu.edu/dissertations/1183.
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Metal Additive Manufacturing (AM) promises an era of highly flexible part production, replete with unprecedented levels of design freedom and inherently short supply chains. But as AM transitions from a technology primarily used for prototyping to a viable manufacturing method, many challenges must first be met before these dreams can become reality. In order for machine users to continue pushing the design envelope, process space must be expanded beyond the limits currently recommended by the machine manufacturers. Furthermore, as usable process space expands and demands for reduced operator burden and mission-critical parts increase, in-situ monitoring of the processes will become a greater necessity. Processing space includes both the parameters (e.g. laser beam power and travel velocity) and the feedstock used to build a part. The correlation between process parameters and process outcomes such as melt pool geometry, melt pool variability, and defects should be understood by machine users to allow for increased design freedom and ensure part quality. In this work, an investigation of the AlSi10Mg alloy in a Laser Powder Bed Fusion (L-PBF) process is used as a case study to address this challenge. Increasing the range (processing space) of available feedstocks beyond those vetted by the machine manufacturers has the potential to reduce costs and reassure industries sensitive to volatile global supply chains. In this work, four non-standard metal powders are successfully used to build parts in an L-PBF process. The build quality is compared to that of a standard powder (supplied by the machine manufacturer), and correlations are found between the mean powder particle diameters and as-built part quality. As user-custom parameters and feedstocks proliferate, an increased degree of process outcome variability can be expected, further increasing the need for non-destructive quality assurance and the implementation of closed-loop control schema. This work presents two Machine Learning-based Computer Vision algorithms capable of autonomously detecting and classifying anomalies during the powder spreading stage of L-PBF processes. While initially developed to serve as the monitoring component in a feedback control system, the final algorithm is also a powerful data analytics tool – enabling the study of build failures and the effects of fusion processing parameters on powder spreading. Importantly, many troubling defects (such as porosity) in AM parts are too small to be detected by monitoring the entire powder bed; for this reason, an autonomous method for detecting changes in melt pool morphology via a high speed camera is presented. Finally, Machine Learning techniques are applied to the in-situ melt pool morphology data to enable the study of melt pool behavior during fusion of non-bulk part geometries.
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Gnanasekaran, Balachander. "A Smoothed Particle Hydrodynamics (SPH) Procedure for Simulating Cold Spray Process - an Additive Manufacturing Process without Heat Supply." University of Cincinnati / OhioLINK, 2018. http://rave.ohiolink.edu/etdc/view?acc_num=ucin1544099572854187.
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Fallon, Jake Jeffrey. "Structure-Process-Property Relationships of Cellulose Nanocrystal Thermoplastic Urethane Composites." Diss., Virginia Tech, 2019. http://hdl.handle.net/10919/103053.
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Nanomaterials are becoming increasingly prevalent in final use products as we continue to improve our understanding of their structure and properties and optimize their processing. The useful applications for these materials extend from new drug delivery systems to improved materials for various transport industries and many more. Nanoscale materials which are commonly used include but are not limited to carbon nanotubes, graphene, silica, nanoclays, and cellulose nanocrystals. The literature presented herein aims to investigate structure-process-property relationships of cellulose nanocrystal (CNC) polymer composites. These CNC nanocomposites are unique in that they provide a dynamic mechanical response when exposed to H2O. Currently, these nanocomposite systems are most commonly solvent cast into their final geometry. In order to enable the use of these materials in more commercial processing methods such as extrusion, we must understand their inherent structure-process-property relationships. To do this, we first characterize the influence of temperature and shear orientation on the unique mechanical adaptive response. Next, the melt processability of the nanocomposite was characterized using material extrusion (MatEx) additive manufacturing (AM). Additionally, the diffusion behavior of water within the film, which controls the dynamic mechanical response, was probed to better predict the concentration dependent behavior. Finally, a literature review is presented which outlines the state of the art for melt extrusion AM of fiber filled polymer composite materials and provides insight into how we can further improve mechanical properties through further addition of composite filler materials.
The initial focus of the dissertation is on the influence of melt processing CNC thermoplastic urethane (TPU) composites and the resulting impact on the mechanical adaptive response. Dynamic mechanical analysis (DMA) fitted with a submersion clamp was used to measure the mechanical softening of the composite while submerged in water. Small angle x-ray scattering (SAXS) and polarized raman spectroscopy were used to qualify the orientation of the various CNC/TPU composite samples. The results of the orientation measurements show that solvent casting the films orient CNCs into a mostly random state and melt extrusion induces some degree of uniaxial orientation. The DMA results indicate that at the processing conditions tested, the uniaxial orientation and thermal exposure from the melt processing do not significantly impact the mechanical responsiveness of the material.
The next objective of this work was to expand upon the aforementioned learnings and determine the CNC composite material processability using MatEx. The ability to process mechanically dynamic CNC/TPU composites with a selective deposition process capable of generating complex geometries may enable new functionality and design freedom. To realize this potential, a two factor (extrusion temperature and extrusion speed) three level (240, 250 and 260 ℃/ 600, 1100 and 1600 mm/min) design of experiments (DOE) was utilized. The resulting printed parts were characterized by DMA to determine their respective mechanical adaptivity. Processing conditions did prove to have a significant impact on the mechanical adaptivity of the printed part. A correlation between applied energy and mechanical adaptivity demonstrates how increasing residence time and temperature can reduce mechanical performance. The shape fixity of the printed parts was calculated to be 80.4% and shape recovery was 44.2%. A 3D prototype part was also produced to demonstrate the unique properties of this material.
Although the understanding of the melt processing behavior of these CNC composites had been improved, a stronger understanding of the moisture diffusion behavior within the composite is required to fully realize and control their potential. Therefore, a study was undertaken to capture the diffusion behavior and correlate it to the mechanical responsive mechanism. To do this, a thermogravimetric sorption analysis (TGA-SA) instrument was used to monitor the mass uptake as a function of time exposed to a humid environment. These data were then compared to DMA data collected for the same samples exposed to a similar degree of humidity. All studies were conducted as a function of concentration in order to better elucidate the influence that percolating network structures may have on the resultant properties. Interestingly, the results show how increasing addition of CNCs results in a decrease in the rate of diffusivity, which is counter to what has been commonly hypothesized. It is hypothesized that increasing CNC content restricts the mobility of surrounding amorphous matrix material, thus increasing the resistance for diffusion of a water molecule. However, the rate of mechanical adaptation was found to increase with increasing CNC content, which is believed to be a result of the increased connectivity, enabling further transport of water molecules.<br>Doctor of Philosophy
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Obidigbo, Chigozie Nwachukwu. "A Numerical and Experimental Investigation of Steady-State and Transient Melt Pool Dimensions in Additive Manufacturing of Invar 36." Wright State University / OhioLINK, 2017. http://rave.ohiolink.edu/etdc/view?acc_num=wright1503493366168339.
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Habib, MD Ahasan. "Designing Bio-Ink for Extrusion Based Bio-Printing Process." Diss., North Dakota State University, 2019. https://hdl.handle.net/10365/32045.
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Tissue regeneration using in-vitro scaffold becomes a vital mean to mimic the in-vivo counterpart due to the insufficiency of animal models to predict the applicability of drug and other physiological behavior. Three-dimensional (3D) bio-printing is an emerging technology to reproduce living tissue through controlled allocation of biomaterial and cell. Due to its bio-compatibility, natural hydrogels are commonly considered as the scaffold material in bio-printing process. However, repeatable scaffold structure with good printability and shape fidelity is a challenge with hydrogel material due to weak bonding in polymer chain. Additionally, there are intrinsic limitations for bio-printing of hydrogels due to limited cell proliferation and colonization while cells are immobilized within hydrogels and don’t spread, stretch and migrate to generate new tissue. The goal of this research is to develop a bio-ink suitable for extrusion-based bio-printing process to construct 3D scaffold. In this research, a novel hybrid hydrogel, is designed and systematic quantitative characterization are conducted to validate its printability, shape fidelity and cell viability. The outcomes are measured and quantified which demonstrate the favorable printability and shape fidelity of our proposed material. The research focuses on factors associated with pre-printing, printing and post-printing behavior of bio-ink and their biology. With the proposed hybrid hydrogel, 2 cm tall acellular 3D scaffold is fabricated with proper shape fidelity. Cell viability of the proposed material are tested with multiple cell lines i.e. BxPC3, prostate stem cancer cell, HEK 293, and Porc1 cell and about 90% viability after 15-day incubation have been achieved. The designed hybrid hydrogel demonstrate excellent behavior as bio-ink for bio-printing process which can reproduce scaffold with proper printability, shape fidelity and higher cell survivability. Additionally, the outlined characterization techniques proposed here open-up a novel avenue for quantifiable bio-ink assessment framework in lieu of their qualitative evaluation.
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Prabhu, Avinash W. "Improving Fatigue Life of LENS Deposited Ti-6Al-4V through Microstructure and Process Control." The Ohio State University, 2014. http://rave.ohiolink.edu/etdc/view?acc_num=osu1388768129.
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Fisher, Brian A. "Part Temperature Effects in Powder Bed Fusion Additive Manufacturing of Ti-6Al-4V." Research Showcase @ CMU, 2018. http://repository.cmu.edu/dissertations/1154.
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To ensure the widespread adoption of metal Additive Manufacturing (AM) processes, a complete understanding of the interactions between process variables is necessary. The process variables of beam power, beam velocity, deposition geometry, and beam diameter have been shown in prior works to have major effects on resultant melt pool and solidification characteristics, but this list is incomplete. Without accounting for part temperatures prior to deposition, unintended outcomes may result. In the current work, Ti-6Al-4V is studied in the Powder Bed Fusion (PBF) processes to gain an in-depth understanding of how part temperature interactions with other process variables affect physical properties of the process such as melt pool size and variability, part distortion, porosity, and microstructural characteristics. This research is performed through a combination of finite element modelling, single melt track experiments, full part production, and in-situ monitoring in order to gain a full understanding of the underlying relationships between part temperature and part outcomes. In the Arcam Electron Beam Melting (EBM®) process, this knowledge is used to generate a feedback control strategy to constrain prior beta grain width to remain constant while part surface temperatures are allowed to vary. In the Laser Powder Bed Fusion (LPBF) process, deposition is investigated at elevated substrate temperatures and several findings show that unintended part temperature increases can lead to undesirable consequences while prescribed part temperature changes can increase the available processing window and allow for more uniform deposition. This work also shows that both global temperature changes due to substrate heating and local temperature changes due to the choice of scan strategy can be combined into one metric: the temperature encountered by the melt pool during deposition. A combination of destructive and non-destructive characterization methods are utilized to understand and measure the changes to the melt pool and microstructural development that are seen during deposition. The feasibility of using a commercial high speed camera as a tool for thermography is characterized and the ability to discern cooling rates and thermal gradients within and surrounding the melt pool provide validation for trends in melt pool properties generated from simulations. This work provides a greater understanding of the role of part temperature during deposition and presents methodologies to account for the changes to the melt pool and resultant part due to both prescribed and unintended temperature changes during deposition.
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Rodriguez, Ricardo Xavier. "Characterization of direct print additive manufacturing process for 3D build of a carbon nanostructure composite." Thesis, The University of Texas at El Paso, 2014. http://pqdtopen.proquest.com/#viewpdf?dispub=1564696.
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<p> This project is a focus on characterizing the process for actualizing three dimensional structures out of a carbon nanostructure composite via a direct print additive manufacturing process. Manufacturing parts additively enables for realization of geometrically complex shapes that often times cannot be manufactured any other way. The specificity of a material's properties have to be such, that the processing method can precisely place and bond material to itself in a highly repeatable manner. Commercial materials for additive manufacturing are have been optimized with these goals in mind and, therefore, often times lack the rigor and robustness for many applications.</p><p> The addition of nanomaterials is promising approach to enhance certain properties of AM materials without drastically altering their critical processing characteristics. This study looks into the reinforcing a commercial Stereolithography resin (DSM Somos™ Watershed 11122) with two types of carbon nanostructures (multi-walled carbon nanotubes and carbon nanofibers) in an attempt to improve mechanical characteristics of the bulk material. Related work has shown to not exceed concentrations over .5% (w/v) such that the material is still compliable with the AM technology. This study attempts to exceed these loading ratios, by attempting concentrations of: 1) 1% (w/v) 2) 2.5% (w/v) 3) 5% (w/v) 4) 10% (w/v).</p><p> A direct write system from nScrypt Inc. (Orlando, FL) is implemented as the extrusion method for the nanocomposite materials. An ultra-violet emitting radiation source is paired up with the nScrypt tool form a direct print additive manufacturing process that dispenses material then cures it right after. All the different processing characteristics and control variables are explained in great detail, as well as the design considerations for fabricating a part with this technique. The impact of the control parameters to dispensed features are observed and measured. Statistical data is generated from this for the design of parts to be built with the system.</p><p> Test specimens for mechanical evaluation are designed based off of the parameter measurements and observation of the material within the system. The test specimens are built from the different nanocomposite concentration and a control sample are evaluated until failure under tensile loads. The fractured specimens are imaged under a scanning electron microscope to analyze layer interfaces and fracture characteristics. A thermal evaluation with photo-DSC is done on the materials to document their behavior under elevated temperatures (0°C - 300°C).</p><p> Background on the technologies, materials, and processes is provided first. A through discussions general AM workflow, technology, and history is given. Then a focus into pertinent technologies (Stereolithography) is discussed in detail. A breadth of direct write technologies and applications are introduced with an emphasis in the one (nScrypt, DPAM) utilized in this study. Finally, carbon nanostructures are introduced.</p>
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Chen, Shuai. "Investigation of FEM numerical simulation for the process of metal additive manufacturing in macro scale." Thesis, Lyon, 2019. http://www.theses.fr/2019LYSEI048/document.
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La fabrication additive (FA) est devenue une nouvelle alternative pour la fabrication des pièces dans l'industrie. Cependant, il existe encore des limites pour ce procédé, en particulier la forme finale défavorable et les propriétés macroscopiques indésirables des pièces métalliques construites dans les systèmes de FA. La distorsion ou la fissure due à la contrainte résiduelle de ces pièces pose généralement de graves problèmes pour certains types de technologie de la FA métallique. Dans un système de FA, la qualité finale d'une pièce métallique dépend de nombreux paramètres de procédé, qui sont normalement optimisés par une série d'expériences sur des machines de FA. La simulation macroscopique dédiée au procédé de FA est une alternative potentielle pour les pièces métalliques fabriquées par la fabrication additive. Dans cette thèse, nous étudions d'abord le pré-processing de la simulation de FA par la méthode des éléments finis (FEM). Le procédé de fabrication additive est un phénomène multi-physique des champs couplés (champs thermique, mécanique et métallurgique). La simulation macroscopique est réalisée à deux niveaux différents. Au niveau de la couche, la reconstruction du modèle 3D est effectuée à partir du fichier de chemin de balayage de la machine de FA, basée sur la manipulation inverse de l'algorithme d'offsetting-clipping. Au niveau de la pièce, le modèle 3D de CAO est reconstruit dans un maillage des voxels, ce qui est pratique pour une pièce avec une géométrie complexe. Avec les températures de préchauffage différentes et les paramètres du procédé différents, la contrainte résiduelle d'une pièce est analysée. Ces simulations impliquent la technique potentielle pour réduire la contrainte résiduelle par l'optimisation des paramètres du procédé, au lieu de moyens traditionnels par augmenter la température de préchauffage. Basées sur la plateforme de simulation de FEM ci-dessus, deux simulations au niveau de ligne sont également étudiées dans cette thèse, visant à la relation entre le procédé de FA et la qualité finale de la pièce. Ces exemples démontrent la possibilité d'utiliser des simulations macroscopiques pour améliorer le contrôle de la qualité pendant le procédé de FA. Dans la première tâche, l'ensemble de données des paramètres de chauffage et la contrainte résiduelle sont générés par la simulation de FA. La corrélation entre eux est étudiée en utilisant des algorithmes de régression, tel que le réseau neuronal artificiel. Dans la deuxième tâche, un contrôleur de PID pour la boucle de rétroaction puissance-température est intégré dans la simulation de procédé de FA et l'auto-réglage de PID est numériquement étudié au lieu d'utiliser la machine de FA. Les deux tâches montrent le rôle important de la simulation de procédé macroscopique de FA, qui peut remplacer ou combiner les nombreuses expériences essai-erreur dans la fabrication additive métallique<br>Additive manufacturing (AM) has become a new option for the fabrication of metallic parts in industry. However, there are still some limitations for this application, especially the unfavourable final shape and undesired macroscopic properties of metallic parts built in AM systems. The distortion or crack due to the residual stress of these parts leads usually to severe problems for some kinds of metal AM technology. In an AM system, the final quality of a metallic part depends on many process parameters, which are normally optimized by a series of experiments on AM machines. In order to reduce the considerable time consumption and financial expense of AM experiments, the numerical simulation dedicated to AM process is a prospective alternative for metallic part fabricated by additive manufacturing. Because of the multi-scale character in AM process and the complex geometrical structures of parts, most of the academic researches in AM simulation concentrated on the microscopic melting pool. Consequently, the macroscopic simulation for the AM process of a metallic part becomes a current focus in this domain. In this thesis, we first study the pre-processing of AM simulation on Finite Element Method (FEM). The process of additive manufacturing is a multi-physics problem of coupled fields (thermal, mechanical, and metallurgical fields). The macroscopic simulation is conducted in two different levels with some special pre-processing work. For the layer level, the reconstruction of 3D model is conducted from the scan path file of AM machine, based on the inverse manipulation of offsetting-clipping algorithm. For the part level, the 3D model from CAD is reconstructed into a voxel-based mesh, which is convenient for a part with complex geometry. The residual stress of a part is analysed under different preheat temperatures and different process parameters. These simulations imply the potential technique of reducing residual stress by the optimisation of process parameters, instead of the traditional way by increasing preheat temperature. Based on the FEM simulation platform above, two simulations at line level are also studied in this thesis, aiming at the relation between the AM process and part's final quality. These examples demonstrate the feasibility of using macroscopic simulations to improve the quality control during the AM process. In the first task, dataset of heating parameters and residual stress are generated by AM simulation. The correlation between them is studied by using some regression algorithm, such as artificial neural network. In the second task, a PID controller for power-temperature feedback loop is integrated into AM process simulation and the PID auto-tuning is numerically investigated instead of using AM machine. Both of the two tasks show the important role of AM macroscopic process simulation, which may replace or combine with the numerous trial and error of experiments in metal additive manufacturing
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Segerstark, Andreas. "Additive Manufacturing using Alloy 718 Powder : Influence of Laser Metal Deposition Process Parameters on Microstructural Characteristics." Licentiate thesis, Högskolan Väst, Avd för tillverkningsprocesser, 2015. http://urn.kb.se/resolve?urn=urn:nbn:se:hv:diva-8796.
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Additive manufacturing (AM) is a general name used for production methodswhich have the capabilities of producing components directly from 3D computeraided design (CAD) data by adding material layer-by-layer until a final component is achieved. Included here are powder bed technologies, laminated object manufacturing and deposition technologies. The latter technology is used in this study.Laser metal deposition using powder as an additive (LMD-p) is an AM processwhich uses a multi-axis computer numerical control (CNC) machine or robot toguide the laser beam and powder nozzle over the deposition surface. Thecomponent is built by depositing adjacent beads layer by layer until thecomponent is completed. LMD-p has lately gained attention as a manufacturing method which can add features to semi-finished components or as a repair method. LMD-p introduce a low heat input compared to arc welding methods and is therefore well suited in applications where a low heat input is of an essence. For instance, in repair of sensitive parts where too much heating compromises the integrity of the part.The main part of this study has been focused on correlating the main processparameters to effects found in the material which in this project is the superalloy Alloy 718. It has been found that the most influential process parameters are the laser power, scanning speed, powder feeding rate and powder standoff distance and that these parameters has a significant effect on the dimensionalcharacteristics of the material such as height and width of a single deposit as wellas the straightness of the top surface and the penetration depth.To further understand the effects found in the material, temperaturemeasurements has been conducted using a temperature measurement methoddeveloped and evaluated in this project. This method utilizes a thin stainless steel sheet to shield the thermocouple from the laser light. This has proved to reduce the influence of the emitted laser light on the thermocouples.
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Berglund, Lina, Filip Ivarsson, and Marcus Rostmark. "Crucial Parameters for Additive Manufacturing of Metals : A Study in Quality Improvement." Thesis, KTH, Skolan för industriell teknik och management (ITM), 2019. http://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-254785.
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Production by Additive Manufacturing creates opportunities to make customized products in small batches with less material than in traditional manufacturing. It is more sustainable and suitable for niche products, but entails new production demands to ensure quality. The goal of this study is to define the most crucial parameters when creating Additive Manufactured products in metal and suggest tools for quality improvement. This is done by analysing earlier studies and evaluating the standard production procedures for manufacturing by Selective Laser Melting. The results from this study stated that porosity and insufficiencies in shape are the most common factors leading to deviation in quality. To avoid it, the most crucial parameters to consider are; The laser freeform fabrication-system related parameters, hatch distance, laser power, layer thickness, fscanning pattern, scan speed and flowability of the powder. Concluded is also that crucial parameters within additive manufacturing are very dependent on the definition of quality for a certain product and can therefore vary. By continuous collection and analysis of data, the task of improving quality will be simplified.<br>Produktion genom Additiv Tillverkning möjliggör tillverkande av skräddarsydda produkter i små batcher och med mindre material än vid traditionell tillverkning. Det är ett mer hållbart tillverkningssätt och mer passande för nischprodukter, men innebär nya produktionskrav för att säkerhetsställa bra kvalitet. Målet med denna studie är att definiera de viktigaste parametrarna vid Additiv Tillverkning av produkter i metall och föreslå verktyg för att förbättra dem. Detta genom analys av tidigare studier och utvärdering av klassiska produktionsrutiner för Selective Laser Melting. Resultaten från denna studie visar att porositet och formfel är de vanligaste faktorerna som leder till bristande kvalitet. För att undvika detta är de viktigaste parametrarna att ta i beaktande; parametrar kopplade till "laser freeform fabrication"-system, distans mellan laserstrålar, kraft på lasern, lagertjocklek, skanningsmönster, fart på skanningen och flytbarhet på pulvret. Slutsatsen pekar även på att avgörande parametrar inom Additiv Tillverkning beror på definitionen av kvalitet för en speciell produkt och kan därför variera. Genom kontinuerlig insamling och analys av data kommer förbättringen av kvalitet förenklas markant.
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Chatham, Camden Alan. "Property-Process-Property Relationships in Powder Bed Fusion Additive Manufacturing of Poly(phenylene sulfide): A Case Study Toward Predicting Printability from Polymer Properties." Diss., Virginia Tech, 2020. http://hdl.handle.net/10919/100053.
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Powder bed fusion (PBF) is one of seven technology modalities categorized under the term additive manufacturing (AM). Beyond the advantages of fabricating complex geometries and the "tool-less manufacturing" paradigm common to all types of AM, polymer PBF shows potential for significant industrial relevance through exploiting the technique's characteristic powder-filled bed (a.k.a. build piston) to utilize the full printer volume for batch-style production. Although PBF should be a suitable processing technique for all semi-crystalline polymers, the polyamide family currently occupies around 90% of the commercial market for polymer PBF. This commercial dominance of polyamides is mirrored in the focus of research publications.
The lack of chemical variety in published research questions the universality of reported Structure-Property-Process and Process-Structure-Property relationships for PBF. This dissertation presents the findings from identifying Structure-Property-Process relationships critical to fabricate multi-layer parts for poly(phenylene sulfide) (PPS) by PBF towards expanding PBF material selection and evaluating universality of relationship guidelines. PPS is an engineering thermoplastic used for its high strength, rigidity, dielectric properties, and chemical resistance at elevated temperatures. These properties are attributed to PPS' highly crystalline morphology. Its current use in the automotive and aerospace industries, which are early adopters of AM technologies, makes PPS a prime candidate for AM applications. Therefore, the goal of this work is to demonstrate PPS printing by PBF, study its behavior throughout the PBF lifecycle, and abstract general trends in polymer PBF relationships.
First, theoretical ranges for print parameter values are determined from properties of an experimental grade PPS powder feedstock. Successful printing of PPS by PBF is demonstrated in a way contrary to published empirical polymer-PBF relationships. Low temperature printing (i.e., bed temperature more than 15 °C lower than polymer peak melting temperature) of PPS successfully fabricated dimensionally accurate parts with reasonable mechanical properties compared against injection molding values. This distinct PPS behavior does not follow empirical guidelines developed for either polyamides or poly(aryl ether ketones).
The unique success of low-temperature PBF prompted further investigation into potential benefits of low-temperature printing. Structure-Property-Process relationships were characterized over the course of simulated powder reuse to show that low-temperature printing prolonged the time when PPS powder properties remained in the "printable" range. Significantly re-used PPS powder was shown to be printable when print parameters were adjusted to accommodate structure and property changes. Successful prints from reused powder is uncommon among published reports of PBF printing of high-performance engineering thermoplastics.
Observations of a change in molecular architecture through branching and crosslinking during simulated powder reuse motivated investigating if similar reactions occur in printed parts. PPS is commonly used at elevated temperatures in the presence of oxygen, which is the ideal environment for branching and crosslinking. Structural changes manifested in increased glass transition temperature and high temperature storage modulus. The relative change in structure when printed parts were thermo-oxidatively exposed was observed to be significant for parts printed from new powder, but minimal for parts printed from reused powder. This is a result of the structural changes occurring as powder feedstock during reuse over multiple builds.
The changing architecture of reused PPS exposed shortcomings with print parameter value selection based solely on polymer thermal properties. Branching and crosslinking reduced crystallinity, resulting in calculated less energy required to melt; however, it also increased melt viscosity. This negative impact on coalescence behavior was not reflected in the methodology for process parameter value determination because current guidelines neglect rheological properties. These observations motivated proposing a method for selecting print settings based on polymer coalescence behavior. Because it is based on coalescence, this method can predict the transition in governing physics from viscous coalescence to bubble diffusion, which is accompanied by a change in the dependence of mechanical properties on laser energy density.
Most work in polymer PBF has focused on "printed part triad'" Process-Property relationships. Work presented in this dissertation contributes to the "printability triad'" of Structure-Property-Process relationships and does so using the novel-to-PBF polymer, PPS. Additional polymers must be explored to continue to discern which polymer-manufacturing relationships are universal among all polymers and which are specific to one subset. The observations and connected interpretation to principles of polymer physics add to the body of knowledge for the polymer PBF field. These contributions will help pave the way for investigations into other polymer families and will re-shape the field's normative logic use when answering the question "what makes a polymer printable by PBF?" Understanding the connection between polymer properties and physical stimuli characteristic of PBF manufacturing will result in parts tailored for specific applications and more sustainable manufacturing, thus realizing additive manufacturing's full potential.<br>Doctor of Philosophy<br>Powder bed fusion (PBF) is one of seven distinct additive manufacturing (AM, also known as ``3D printing'') technologies. The manufacturing process creates solid, three-dimensional shapes through selectively heating, melting, and fusing together polymer powder particles in a layer-by-layer manner. Currently, organizations are interested in complementing existing manufacturing technology with PBF for one of three general reasons: (1) "complexity is free" PBF has the ability to make shapes that are difficult or expensive to fabricate using other manufacturing technologies. (2) "tool-less manufacturing" PBF only requires a digital design file to fabricate objects. This enables small changes to be easily made via computer-aided design (CAD) programs without the need to invest time and money into tooling (e.g., molds, jigs, fixtures, or other product-specific tools). This enables "mass customized" products (e.g., custom-fit medical devices and implants) to be economically feasible. (3) "material efficiency" AM is attractive as it often generates less waste than subtractive manufacturing techniques like milling. This is particularly a concern for organizations that manufacture parts from expensive, high-performance polymers, such as in the aerospace and medical industries. Despite these benefits, the state of the art for polymer PBF has room for improvement. Specifically, there are many details regarding material behavior during PBF manufacturing that are unknown; any unknown behaviors present challenges to building confidence in production quality. Additionally, approximately 90% of current PBF use is nylon-12 or else another material in the polyamide family of semi-crystalline thermoplastics. This limited selection of commercially available materials compared against other forms of manufacturing contributes to PBF's circular quandary: the manufacturing process physics are not robustly understood because most experimentation and research has been carried out on one family of polymers; however, a wider variety of polymers has not been developed because there is a limited understanding of the process physics.
This dissertation presents research toward answering both PBF challenge areas. The first three chapters present investigations into relationships between the properties of a novel, experimental grade poly(phenylene sulfide) (PPS) semi-crystalline thermoplastic polymer powder, the stimuli imposed on this polymer during PBF processing, and the resultant properties of printed parts (i.e., "property-process-property relationships"). The target polymer, poly(phenylene sulfide), is a high-temperature, high-performance polymer that is traditionally melt processed, but has not yet been commercialized for PBF. Prior literature has established mathematical representation for the interaction between manufacturing energy input and the thermal response of the polymer resulting in melting. This framework has been created through studying the polyamide family. Work presented in this dissertation evaluates existing guidelines for PBF process parameter selection using measured thermal behavior of PPS (i.e., a polysulfide, not a polyamide) to predict the range of manufacturing energies affecting geometrically accurate printed parts of high density and strength. In addition, the impact of thermal exposure from repeated PPS powder reuse over the course of multiple PBF prints was evaluated on powder, thermal, and rheological properties identified as critical for PBF printing. Changes to the molecular structure and properties of reused PPS powder were observed to follow different trends than those reported for other materials traditionally used. The effect of thermal exposure on printed parts was also investigated to determine if the observed changes in molecular structure occurring during thermal exposure of the powder would result in changes to mechanical performance properties of printed parts.
The importance of rheological flow properties in dictating printed part performance was observed to be a common theme throughout working with PPS. The final chapter presents a novel method for quantitatively predicting particle fusion during PBF and connecting the extent of particle fusion to mechanical properties of printed parts. The presented method is "polymer agnostic" and advances the state of the art in understanding the physics guiding polymer response to stimuli imposed during PBF AM.
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Johansson, Kenny. "Process and microstructure development of a LPBF produced maraging steel." Thesis, Karlstads universitet, Avdelningen för maskin- och materialteknik, 2020. http://urn.kb.se/resolve?urn=urn:nbn:se:kau:diva-79004.
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Additive manufacturing (AM) has the possibility of producing complex-shaped components which can not be produced by conventional manufacturing methods. This gives the opportunity for designers to freely think outside the design spectra which is otherwise limited by conventional manufacturing methods. AM of metal has rapidly been developed for the last three decades, and they now are reaching industrial acceptance levels, metal feedstock for use in AM is also rapidly growing. AM of metals is especially of interest for the tooling industry. The design freedom which AM offers the tooling manufacturer can design complex cooling channels within moulds, which could reduce cycle time and enhance the quality of components produced with the moulds. Maraging steels have been proven to both be able to be processed with AM but also have comparable performance to traditionally carbon-based used tool steels. Laser Powder Bed Fusion (LPBF) is one of the most promising AM systems today, by using powder as a feedstock it can produce high-resolution parts without needing to process them after they have been produced. However, there is a need to better understand processing within the LPBF system. This master thesis is aimed to process a newly developed maraging steel from Uddeholm, and conduct process parameter experiment and study their correlation to be able to produce samples with as few defects possible. It is crucial to conform to a good methodology for how to find those correlations and see how they influence the printed material. LPBF process has a multi-complex variable system, and by narrowing down the complexity by focus on the most influencing parameters as has been proven by many researchers. Even with a reduced focus, it is still a multi-variable problem. In this study a methodology of finding process parameters relations, a Design Of Experiment software was used, namely, MODDE. By screening of process parameter ranges, within the software, a statistical evaluation of operational process window can be found with fewer conducted experiment. Development of process parameter can traditionally be time-consuming and result in an unnecessary large number of experiments to find the operational window. The experiment showed that laser power and point distance had the most influencing effect on relative density, followed by exposure time and hatch distance. The experiment was firstly conducted with a layer thickness of 50 µm, the achieved relative density resulted in over 99.8 percent. However, a large lack of fusion defects was observed inside the specimens. Even though a high relative density was measured, a pore analysis has to be conducted to fully understand the size and shape of defects since they can have a severe impact on mechanical properties. It was believed that the layer thickness was too high and that the defects could be reduced by printing a set with same process parameters but with a lower layer thickness of 40 µm instead. The reduction of layer thickness did result in a significant decrease of the defects observed. However, future work after this thesis must be continued to further optimize and to increase the solidity of printed material to reach closer to its conventional produced relatives<br>Additiv tillverkning har möjligheten att producera komplext konstruerade komponenter som inte kan produceras med konventionella tillverkningsmetoder. Detta ger konstruktörer möjligheten att fritt tänka utanför designspektra som annars begränsas av konventionella tillverkningsmetoder. Additiv tillverkning av metall har snabbt utvecklats under de senaste tre decennierna och har nu nått industriella acceptansnivåer. Metallråvara för användning i additiv tillverkning växer snabbt. Additiv tillverkning av metaller är särskilt intressant för verktygsindustrin, designfriheten som additiv tillverkning kan erbjuda verktygstillverkaren för att kunna utforma komplexa kylkanaler inuti formar. Det kan således reducera cykeltiden och förbättra kvaliteten på komponenter som produceras med formarna. Maråldringsststål har visat sig att både kunna processas i additiv tillverkning och har jämförbara egenskaper med traditionellt kolbaserade verktygsstål. Pulverbäddsystemet är ett av de mest lovande systemen idag, genom att använda pulver som råmaterial kan systemet producera komponenter med hög noggranhet utan att behöva bearbeta dem efter att processen är klar. Det finns emellertid ett behov av att bättre förstå själva processen inom pulverbädds teknologin. Den här masteruppsatsen syftar till att additivt tillverka ett nyutvecklat maråldringsstål från Uddeholm. Samt att genomföra processparameterexperiment och studera deras korrelation för att kunna producera prover med så få defekter som möjligt. Det är avgörande att hitta en metod för hur man hittar korrelationerna och se hur de påverkar det tillverkade materialet. Pulverbäddsystemet har ett multikomplext variabelsystem. För att minska komplexiteten kan fokus läggas på de mest inflytelserika processparametrarna, vilket har bevisats av många forskare. Även med ett reducerat fokus är det fortfarande ett flervariabelsproblem. I denna studie användes en metod för att hitta relationer mellan processparametrar och en Design Of Experiment-programvara, nämligen MODDE. Genom screening av processparametrar, inom programvaran, kan en statistisk utvärdering av operativt processfönster hittas med färre genomförda experiment. Utvecklingen av processparametrar kan traditionellt vara tidskrävande och resultera i ett onödigt stort antal experiment för att hitta det operativa fönstret av processparametrar. Experimentet visade att lasereffekt och punktavstånd påverkande den relativa densiteten mest, följt av exponeringstiden och spåravståndet. Experimentet genomfördes först med en lagertjocklek av 50 mikrometer, lagertjockleken resulterade i en relativ densitet på över 99,8 procent. Emellertid observerades stora fusionsdefekter inuti proverna. Även om en hög relativ densitet mättes, måste en poranalys genomföras för att fullt ut förstå storleken och formen på defekter eftersom de kan ha en avgörande inverkan på mekaniska egenskaperna. Det misstänktes att lagertjockleken var för hög och att defekterna kunde minskas genom att tillverka en ytterligare uppsättning av samma processparametrar men med en lägre lagertjocklek på 40 mikrometer istället. Minskningen av lagertjockleken resulterade i en signifikant minskning av de observerade defekterna. Framgent efter den här avhandlingen måste dock arbetet fortsätta att ytterligare optimera och öka soliditeten i det additivt tillverkade materialet. Det för att uppnå bättre prover och komma ännu närmre det konventionellt tillverkade materialets egenskaper.
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D'Amico, Tone Pappas. "Predicting Process and Material Design Impact on and Irreversible Thermal Strain in Material Extrusion Additive Manufacturing." Digital WPI, 2019. https://digitalcommons.wpi.edu/etd-dissertations/572.
Full textAbstract:
Increased interest in and use of additive manufacturing has made it an important component of advanced manufacturing in the last decade. Material Extrusion Additive Manufacturing (MatEx) has seen a shift from a rapid prototyping method harnessed only in parts of industry due to machine costs, to something widely available and employed at the consumer level, for hobbyists and craftspeople, and industrial level, because falling machine costs have simplified investment decisions. At the same time MatEx systems have been scaled up in size from desktop scale Fused Filament Fabrication (FFF) systems to room scale Big Area Additive Manufacturing (BAAM). Today MatEx is still used for rapid prototyping, but it has also found application in molds for fiber layup processes up to the scale of wind turbine blades. Despite this expansion in interest and use, MatEx continues to be held back by poor part performance, relative to more traditional methods such as injection molding, and lack of reliability and user expertise. In this dissertation, a previously unreported phenomenon, irreversible thermal strain (ITε), is described and explored. Understanding ITε improves our understanding of MatEx and allows for tighter dimensional control of parts over time (each of which speaks to extant challenges in MatEx adoption). It was found that ITε occurs in multiple materials: ABS, an amorphous polymer, and PLA, a semi-crystalline one, suggesting a number of polymers may exhibit it. Control over ITε was achieved by tying its magnitude back to part layer thickness and its directionality to the direction of roads within parts. This was explained in a detail by a micromechanical model for MatEx described in this document. The model also allows for better description of stress-strain response in MatEx parts broadly. Expanding MatEx into new areas, one-way shape memory in a commodity thermoplastic, ABS, was shown. Thermal history of polymers heavily influences their performance and MatEx thermal histories are difficult to measure experimentally. To this end, a finite element model of heat transfer in the part during a MatEx build was developed and validated against experimental data for a simple geometry. The application of the model to more complex geometries was also shown. Print speed was predicted to have little impact on bonds within parts, consistent with work in the literature. Thermal diffusivity was also predicted to have a small impact, though larger than print speed. Comparisons of FFF and BAAM demonstrated that, while the processes are similar, the size scale difference changes how they respond to process parameter and material property changes, such as print speed or thermal diffusivity, with FFF having a larger response to thermal diffusivity and a smaller response to print speed. From this experimental and simulation work, understanding of MatEx has been improved. New applications have been shown and rational design of both MatEx processes and materials for MatEx has been enabled.